PEMILIHANMATERIAL
TEKNIK UNTUK APLIKASI DI
INDUSTRI
Dr.Ir. Slameto Wiryolukito Program Studi Teknik Material
Institut Teknologi Bandung [email protected]
022-250-2457; 022-250-8144; 0815-7055525
Material Eng. Dept. of ITB 1
JENIS MATERIAL TEKNIK LOGAM
Berbasis Besi: Steel, Cast Iron, Stainless Steel, Iron Base Super
Alloy (70% kebutuhan) Berbasis Tembaga: Cu (cp) Brass, Bronze Berbasis Aluminium: Seri 2xxx s/d 7xxx Berbasis Titanium: Ti-Al-V; Ti (cp) Berbasis Nikel: Ni (cp), Ni-Base Super Alloy
POLIMER: PE; PP; PTFA; KERAMIK:
Berbasis Oksida, Karbida, Nitrida KOMPOSIT:
Polimer berpenguat Keramik: GFRP; CFRP Polimer berpenguat Logam: ban mobil Logam berpenguat Keramik: CerMet
Material Eng. Dept. of ITB 2
Contoh Aplikasi
a. Oil & Gas Industries: Pipeline, Piping, HE,Vessel, Column, Tanks
b. Power Generation: PLTU; PLTG; PLTP; PLTA
c. Automotive & Transport Vehicles: Cars,Motorcycles, Trains, Buses,
Airplanes,
Ships,Tankers, Bridges,
Harbord. Medical Purposes
e. Housing & Building
f. House wares
Material Eng. Dept. of ITB 3
Material Eng. Dept. of ITB
Contoh Aplikasi
4
Material Eng. Dept. of ITB 5
PERTIMBANGAN UMUM
Sasaran dari Pemilihan Material: Menyediakan material yang memenuhi
persyaratan kerja suatu komponen dengan memerhatikan
Fabrikasi menjadi komponen tidak sulit (welding, forming, casting, dst) Harga memadai Waktu pengadaan tidak lama (ketersediaan, lokasi asal, embargo)
Keperluan: Produksi komponen baru (saat FEED: Front End Engineering Design) Modifikasi peralatan
Perawatan dan Perbaikan
Material Eng. Dept. of ITB 6
Beban saat Kondisi Kerja Komponen Beban Mekanik:
Gaya, Momen Bending, Momen Torsi bersifat Statik, Dinamik (putaran), Kejut
Beban Termal: Tmaks, Tmin bersifat Isotermal, Siklus, Kejut
Beban Listrik Beban Lingkungan Kerja:
Temperatur sekitar, Korosivitas (Oksidasi, Karburasi, Posfidasi, Nitridasi, Asam, Basa, CO2, H2S, Cl-, dst)
Beban Saat Fabrikasi, Transportasi & Penyimpanan Akibat metal forming: rolling, forging, coiling, packaging Akibat pemanasan: welding, heat treatment Lingkungan saat transport & penyimpanan
Material Eng. Dept. of ITB 7
Dasar Acuan Pemilihan Material Bagi Pengguna: SANGAT BANYAK PILIHAN: Jenis dan Tipe Material Di Pasaran SANGAT LUAS PENAWARAN: Sifat Mekanik, Sifat Teknologi, dan Ketahanan
Lingkungan
Be Smart “I Know What I Want” – “Ku Tahu Yang Ku Mau”
PILIHAN: PROVEN TRACK RECORDS: Jenis Material, Keandalan Produsen STANDARD & Spesifikasi Material
International: SNI, ASTM, JIS, DIN, BS, AFNOR, AS Perusahaan: EXXON, SANDVICK, NORSOK, DNV Profesi: Militer, NACE; API, ASME
MATERIAL BARU Seringkali Belum Distandarkan Tingkat Resiko Tinggi
Perlu dilakukan Trial
Material Eng. Dept. of ITB 8
STANDAR NORSOK (M-001)OIL AND GAS PRODUCTION AND PROCESSING
Equipment
Material
Wellhead equipment/X-mast trees 13Cr4Ni, Low Alloy Steel with alloy625 weld overlay
Piping and vessels 22Cr Duplex, 25Cr Duplex, 6Mo, 316
Thick wall vessel Carbon steel with 316, Alloy 625, Alloy
825 or 904 clad or weld overlay
Piping and Vessels in low corrosivitysystem
Carbon steel
Inlet side of compressor Carbon steel, Carbon steel with CRAweld overlay or solid CRA if require, based upon corrosivity evaluation
Piping, vessels for produced water 316, 22Cr duplex, 25Cr duplex, 6Mo, Titanium or GRP.
Material Eng. Dept. of ITB 9
APA YANG TERCANTUM DALAM STANDAR MATERIAL? Tipikal Aplikasi: untuk Pressure Vessel, Boiler, Piping di Temp
Rendah, dst Korelasi dengan Standard Material Lainnya Persyaratan Kualitas dikaitkan dengan Proses Produksinya Komposisi Kimia Proses Perlakuan Panas (Heat Treatment) Maksimum Pengotor yang dibolehkan
Sifat Mekanik (Tensile Strength, Yield Strength, Elongtion, Hardness, Impact Value)
“PERLU PENGETAHUAN DASAR MATERIAL TEKNIK”
Material Eng. Dept. of ITB 10
STUDIKASUS
Material Eng. Dept. of ITB 11
Material SelectionsFor Oil and
GasProduction Facilities(Case: Internal Corrosion)
Dr.Ir. Slameto Wiryolukito Material Engineering Department Bandung
Institute of Technology
12
INTRODUCTION
The recent Oil and Gas explorations turn to fields having more aggressive fluids
Typical corrosive agents in Oil & Gas production facilities: CO2, H2S, Cl-, O2. Typical Fluid Conditions:
CO2 up to 5% mole H2S up to 500 ppm Cl- up to 25,000 ppm
Other contributing factors to corrosion: Water Cut, High T, High P, Low pH, Flow Rate, Erosion
Material Eng. Dept. of ITB 13
CO2Corrosion(“Sweet” Corrosion) It applies to any production fluid containing CO2 Gas
together w/ Water Potential to corrode facilities upstream of the dehydration units
CO2 + H2O —> H2CO3
Fe + H2CO3 —> FeCO3 + H2
It address to Top Of Line (TOL) or Dew Point Corrosion & Bottom Of Line (BOL) or Bulk Water Corrosion
CO2 in Gas and Oil Productions Any water in contact w/ gas will dissolve CO2 Oil production containing water will readily dissolve CO2 Corrosivity is proportional to partial pressure of, pCO2
pCO2 = mol% CO2 x Total Gas-Pressure
pCO2 < 7 psia ; no corrosive
7 psia < pCO2 <30 psia ; mild corrosion pCO2 > 30 psia ; severe corrosion
14
Contributing Factorsto CO2
Corrosion Temperature & Scales (FeCO3 and F3O4 ):
CO2 corrosion susceptible at T below saturated steam temp(T<85oC); Maximum CR occurs at T ≅
60oC FeCO3 and F3O4 scales formation suppress the CR
expressed as Scale Factor; common practice Scale Factor= 0.85 At pH > 6; Higher Temp increases possibility of Scale Formation
Pressure: higher P will be more aggressive Flow Regime: controlled by flow rates of Gas, HC-
Liquid, Produced & Formation Water, Eroding Particles, Acetic Acid
Dissolved O2: Aerated or De-aerated conditions Passive Inhibitions: presence of Bicarbonate,
Crude/Condensate, Scales of FeCO3, F3O4, FeS Inhibitors: Type, Efficiency, Availability, Effectivity
Material Eng. Dept. of ITB 15
FormulationsP = Total Pr essure x
⎛ % mole CO2 ⎞ CO2 Partial Pressure
Water Cut
CO 2
⎛⎜⎝
Pr oducedWater
⎟100 ⎠⎞
Water − cut (%) = ⎜ ⎟ x 100%⎝ Pr oducedWater + Condensate ⎠ Scale Factor, fscale
log(f ) = ⎜ 2400 ⎟ − 0.6. log(p ) − 6.7scale
⎛ ⎞⎝ T ⎠ CO 2
H2S Partial Pressure
pCO 2
H 2 S
bara ;
T (K )
⎜ ⎟100
P = Total Pr essure x ⎛ % mole H 2 S ⎞⎝ ⎠
Material Eng. Dept. of ITB 16
Inhibitor Effect
Inhibitor shall suppress the CR Huge variation; track records is important Inhibitor Effectivity = Efficiency x Availability
= 0.90
x 0.90= 0.9
5x 0.9
0= 0.90
x 0.95= 0.9
5x 0.9
5 Inhibitor Efficiency Inhibitor Efficiency = UCR – I CR x 100 %
UCR
Material Eng. Dept. of ITB 17
Inhibitor Effect (cont’d)
INHIBITOR AVAILABILITY 80% availability = 73 days annual downtime
90% availability = 36 days annual downtime
95% availability = 18 days annual downtime
High availability implies: dedicated attention to corrosion inhibition
Immediate repair/refit of injection equipment
use of correct injection equipment
correct dosage rate related to flow rate
Material Eng. Dept. of ITB 18
CO2CorrosionAssessments
CR prediction by: NORSOK; Cassandra (bp- property right); ECE (Liane Smith)
Reynolds number: indication Laminar orTurbulent Flows
Shear Stress Critical Gas Velocity Fugacity
Inhibitor Effectivity
Material Eng. Dept. of ITB 19
CO2CRPrediction [5] CO2 Corrosion in C/S causes a General Corrosion Mode; CR prediction:
De Waard/Milliam’s & SHELL, firstly published in 1975 CORROSION-91: predictive model for CO2 CORROSION-93: predictive of CO2 Cor. of C/S CORROSION-95: considers Fluid Flow Velocity
Flowline7
NORSOK (IFE Norway)
BP-Cassandra
Hydrocorr99
ECE= Electronic Corrosion Engineer (SHELL-Cees de Waard of CorCon, Liane Smith-Intetech Ltd)
Material Eng. Dept. of ITB 20
General Overviewon CR
Predictions Software[5]
NORSOK BP-Cassandra ECEIFE-Shear StressModelNorwegian Oil Co.Considers:
CO2; pH; Flow Regime; Fugacity; Glycol effect; Inhibitor
SHELL Model &Field Experiences
Emphasize on Water Chem; pH & Acetate with respect to ScalingConsiders: CO2;
Flow Regime; Inhibitor; TOLC; H2S
SHELL Model w/Correction Factors
Considers:
CO2; Flow Regime; TOLC; HCO3&Fe+
saturation; H2S; pH; Liq hold-up; HC-liquid
Material Eng. Dept. of ITB 21
H2SCorrosion(“Sour-Corrosion”)
Susceptible to production fluid containing H2S Fe + H2S —> FeS + H2 (overall reaction) 2H+ + 2e- —> 2H (atom) —> H2 (molecule)
FeS is protective film, but breakdown of FeS causes
pitting oreven cracking in most iron base alloys
Hydrogen atoms diffuses to steel to cause cracking SSCC
HIC HIC-SOHIC
NACE MR-0175 for environment w/ pH2S > 0.05 psia considers
“Sour Service”
Material Eng. Dept. of ITB 22
NACE MR 01-75Nomogram
Material Eng. Dept. of ITB 23
SSCC & HIC Testsat Mat’l Eng. Dept.of
ITB
Material Eng. Dept. of ITB 24
Materal Eng. Dept. of ITB
HIC Testing ssembly
i 25
CO2-H2S Corrosion
Existence of CO2 together with H2S will enhance corrosion aggressivity of the fluids
Dominant Corrosion mechanism depends on
PCO2 /PH2S [*]: PCO2 /PH2S < 20 : H2S corrosion is dominant
20 < PCO2 /PH2S < 500 : mixed corrosion
PCO2 /PH2S > 500 : CO2 corrosion is dominant
Material Eng. Dept. of ITB 26
Material Cl- (ppm) pH2S (psia) T ( C )
316 < 10,000, pH > 3.5 < 0.74 < 60
< 50,000, pH > 3.5 < 1.74 < 60
S31254 < 50,000, pH > 3.5 < 14.7 < 150
< 50,000, pH > 5 < 29.4 < 150
22 Cr < 30,000, pH > 3.5 < 0.294 < 150
< 10,000, pH > 3.5 < 1.47 < 150
25 Cr < 50,000, pH > 3.5 < 1.47 < 150
< 50,000, pH > 4.5 < 5.88 < 150
Cl- Effect
Existence of Cl- in production fluid will
Promote general type corrosion in C/S
ClSCC in high grade material (S/S)
Threshold ClSCC susceptibility for S/S [* API 581; Norsok, NACE MR 01-75]:
Cl- > 10,000 ppm; T>60oC; pH < 4.5
Cl- together w/ H2S [Norsok]
Material Eng. Dept. of ITB 27
MIC (Microbially Induced)Corrosion Risk Prediction of CR or knowing when pitting starts due to
MIC is unreliable, instead current practice considers only the susceptibility of equipment/piping
Information required to Evaluate MIC Risk
Water wetting, water cut pH = 5 to 9.5 TDS > 60 g/l, SRB grows T= 10 to 45oC; T>45oC SRB grows Total Carbon from fatty acid > 20
mg/l N > 5 mg/l C/N ratio < 10
Flow Velocity: 1 to 3 m/s Existence debris on pipe bottom Pigging Frequency Prolonged O2 Ingress > 50 ppb Biocide Equipment Age
Material Eng. Dept. of ITB 28
Corrosion Mitigation
Material Eng. Dept. of ITB 29
Corrosion Mitigation
1. Materials Selection (Presented in this Paper)
2. Isolation from the Environment
3. Modification of the Environment
4. Electrical Modification
5. Design
Material Eng. Dept. of ITB 30
MATERIALSELECTIONS
Material Eng. Dept. of ITB 31
MATERIAL PROPERTIES
Material Properties: Mechanical, Chemical (corr.
Resistance), Physical, Technological
Dependable on: Base metals Alloying Elements: type, amount Manufacturing Treatments Microstructures
Material Eng. Dept. of ITB 32
Base Metals
Manufacturing
&
Treatment
s
Microstructure
Material
Properties
Alloying Elements
- Type, Amount
Material Eng. Dept. of ITB 33
Considerations in MaterialSelections
CAPEX versus OPEX
Reduction of hidden costs
Life cycle costs
Overcoming operational restraints
Fit and forget
Environmental aspects
Safety
Material Eng. Dept. of ITB 34
Life Cycle Costs
CAPEX
Material Eng. Dept. of ITB 35
Corrosion
Considerations
UponMaterial
Selections(w/o Residual
Stress)
Material Eng. Dept. of ITB 36
RationalizationinMaterial Selections Us
eC/S Uninhibited, UCR
Use
C/S + Inhibition program,
ICR Use C/S + CP Program (SA; ICCP) Use CRA (Huge variations of CRA)
Solid CRA Clad CRA (Metallurgical Bonding or Mechanical Lining)
Use CRA + CP Program (SA; ICCP) forExternal Corrosion Case
Use Titanium Base Clad
Non Metallic Material (Base or Coating)Material Eng. Dept. of ITB 37
UninhibitedC/S
Operating conditions (T, P, Flow Rate, pH) & Fluid composition (CO2, H2S, Cl-, Acetic Acid, Water Cut, DO, TDS)
Candidate Material of C/S
Grade, Strength, Hardness,Thickness Prediction
UCR
Prediction Un-inhibited Corrosion Allowance,
UCA,max = 8 mm
Economics Considerations: Seamless, Long-seam, Spiral-seam, UOE
ERW, SAW Availability, Delivery Time
Material Eng. Dept. of ITB 38
C/S + Inhibition Program Operating Conditions & Fluid Compositions Candidate Material C/S
Grade, Strength, Hardness, Thickness
Inhibitor Effectivity Inhibitor Efficiency x Inhibitor Availability
Prediction Inhibited CR, ICR Prediction Inhibited, CA
Max ICA = 8 mm
Economics Considerations: Seamless, Long-seam, Spiral-seam, UOE ERW, SAW Availability, Delivery Time
Material Eng. Dept. of ITB 39
CRA(Solid or
Clad) Operating Conditions & Fluid Compositions Candidate Material of CRA
Chem Composition, Grade, Strength, Hardness Solid CRA or, Clad System (Metallurgical Bonding or Mechanical Lining)
Potential Corrosion Atack General Corrosion: Prediction CR and CA Pitting Cracking: SSCC; HIC, ClSCC; SCC; Hydrogen
Crack; Sodium Crack
Economics Considerations;
HUGE VARIATIONS, Length & OD, Availability, Delivery
Time
Material Eng. Dept. of ITB 40
Clad CRA [6]
Material Eng. Dept. of ITB 41
Cracking Mechanisms
Active-Passive transformations
Pitting
Stress Corrosion Cracking
Hydrogen Embrittlement
Corrosion Fatigue
Material Eng. Dept. of ITB 42
Passivation
ETrans- passive zone
Passivezone
Active-passivephenomena
Active Corrosion Zone
Log i
Corrosion Awareness Course 55
Material Eng. Dept. of ITB 43
Pitting Resistance Number
PREN = Cr% + 3.3Mo% + 14N
Material PREN
13 Chrome steel 13
316 Stainless steel 25
317 Stainless steel 31
2205 Duplex stainless steel 34
A219 Super Duplex stainless steel
42
Alloy 825 32
Alloy 625 51
Material Eng. Dept. of ITB 44
Stress Corrosion Cracking
STRESS
ENVIRONMENT
SUSCEPTIBLEMATERIAL Stress
CorrosionCracking
Material Eng. Dept. of ITB 45
Stress Corrosion Cracking
Stainless steels + stress + chloride +temperature
Carbon steels + stress + sulphide
Copper alloys + stress + ammonium compounds
Carbon steels + stress + strong alkali
Material Eng. Dept. of ITB 46
Rat
e o
f cr
ack
gro
wth
Sulphide Stress Cracking
Initiationperiod
Propagation phase Mechanicalfailure
Time
Material Eng. Dept. of ITB 47
Pre
ssu
reRisk of as Systems
Risk of Cracking
No riskof cracking
Hydrogen sulphide concentration
Material Eng. Dept. of ITB 48
Avoiding Sulphide Stress Cracking
• Limitation on strength of material<120,000 psi
• Hardness restrictionRC < 22 or VHN10<248
• Suitable welding procedure• Avoidance of cold work• No arc strikes• Adequate difference between yield
and ultimate strength
Material Eng. Dept. of ITB 49
MATERIAL SELECTIONS(Case Study)
Material Eng. Dept. of ITB 50
Considerations
CO2Effect
H2SEffect;
Susceptibility
to SSC
Cl- Effect; Susceptibility to ClSC
Combination Effects of CO2; H2S; Cl-
Material Eng. Dept. of ITB 51
Inhibitor
Effectivity ====
CO2Effect
CR prediction by: NORSOK; Cassandra (bp-property
right); ECE (Liane Smith) Reynolds number:
indicationLaminar or TurbulentFlows
Shear Stress Critical Gas Velocity Fugacity
Efficiency x Availability0.90 x 0.900.95 x 0.900.90 x 0.95
Materia=l En0g..9De5pt.xof 0IT.B95 52
CO2Effect (cont’d)
INHIBITOR EFFICIENCY Inhibitor Efficiency = UCR – ICR x 100 %
UCR
INHIBITOR AVAILABILITY 80% availability = 73 days annual downtime 90% availability = 36 days annual downtime 95% availability = 18 days annual downtime
High availability implies: dedicated attention to corrosion inhibition Immediate repair/refit of injection equipment use of correct injection equipment correct dosage rate related to flow rate
Material Eng. Dept. of ITB 53
Susceptibility to SSC
NACE MR 01-75
NKKNomogram
SUMITOMONomogram
Membrane Stress Analysis
Material Eng. Dept. of ITB 54
NACE MR 01-75
Consider Multiphase Systems
Consider H2S only (ignores pCO2, T, Cl-)
Comment NACE MR 01-75 considers the environment is still
within non-SSC region but close to border of SSC Region
Mat’l Hardness shall be confirmed to have HRC< 22
Material Eng. Dept. of ITB 55
NACE MR 01-75Nomogram
Material Eng. Dept. of ITB 56
NKKNomogram [2]
Consider p CO2
incorporated with p
H2S
ConsiderCl-
incorporated with
Material Eng. Dept. of ITB
Temp
7
NKKNomogram (cont’d)
Material Eng. Dept. of ITB 58
NKKNomogram (cont’d)
Material Eng. Dept. of ITB 59
SumitomoNomogram [3]
Consider ppH2S incorporated with pp CO2
Consider
Mat’l
Material Eng. Dept. of ITB
strength, T
0
Membrane StressAnalysis
Flowline; Pipeline; Piping ANSI B 31.3
Pressurized Equipment ASME Sect. VIII, Div.1
API 579
Material Eng. Dept. of ITB 61
SUMMARY Technically, one selects material shall
understand the needs
Motto: “Ku Tahu yang Ku Mau” “I Know What I Want”
Should always be
aware: “Material Properties dependon
Chemicalcompositions, Manufacturing, andTreatment
” Ignorance to manufacturing, treatment, and workmanship certainly will ruin an excellent-design
Commercial approach shall no t sacrificed the technical considerations for high safety and reliability guarantee of the production facilities
Material Eng. Dept. of ITB 62
THANK YOU
Material Eng. Dept. of ITB 63
Literature
1. NACEMR01752. NKKOCTGJournal
3. SUMITOMO Journal
4. Roger A. King, “Corrosion
Awareness”
5. AKER KVAERNER presentation6. JSW “Clad Pipe Production
Journal”
Material Eng. Dept. of ITB 64